Laser Hardening Process - Synergy Additive Manufacturing

With experience in laser hardening over 500 large automotive castings and tools, Synergy has built a reputation for excellence. Beyond automotive tooling, our expertise spans industries such as mining, oil & gas, and aerospace. Our carefully optimized process ensures exceptional quality with significantly reduced turnaround times. Unlike conventional hardening techniques like flame or induction hardening, laser heat treatment introduces minimal heat into the part. This results in little to no distortion, eliminating the need for costly post-machining, hard milling, or straightening operations—leading to substantial cost savings.

The Laser Hardening Process at Synergy

Step 1: Pre-Programming Dies Before Arrival

In today’s competitive global market, just-in-time manufacturing is key. Using digital-twin and CAD files for tooling, Synergy pre-programs dies and tooling before they arrive, significantly reducing turnaround times.

Step 2: Dry Run & Robot Tool Path Verification

Step 3: Laser Hardening Process

Synergy’s laser hardening process control system employs advanced algorithms that monitor and regulate temperature within ±1°C in most cases. This precision ensures consistent hardness and depth. The process control system serves as a built-in quality check. For tools with welds, laser hardening is applied close up to—but not on—the weld.

Step 4: Quality Control & Inspection

After laser hardening, each tool undergoes rigorous inspection and ultrasonic hardness testing. A hardness map is provided to ensure full traceability and quality assurance.

At Synergy Additive Manufacturing, our combination of cutting-edge technology, precise process control, and streamlined workflow enables us to meet tight production deadlines without compromising quality. Our skilled technicians further enhance efficiency, ensuring the highest industry standards while achieving rapid turnaround times.